U.S. patent application number 11/335116 was filed with the patent office on 2007-01-18 for console or trim skin for large volumes using a single pre-formed (formed or molded) single skin.
Invention is credited to Peter Anthony Olley, Ian Sutherland Wright.
Application Number | 20070014969 11/335116 |
Document ID | / |
Family ID | 34954942 |
Filed Date | 2007-01-18 |
United States Patent
Application |
20070014969 |
Kind Code |
A1 |
Olley; Peter Anthony ; et
al. |
January 18, 2007 |
Console or trim skin for large volumes using a single pre-formed
(formed or molded) single skin
Abstract
A panel, in particular a covering panel or vehicle lining, is
provided with a one-piece skin having, in the region of its exposed
surface, at least one visual feature with a linear structure
imitating or simulating a functional construction, such as a sewing
operation. This skin is mounted on a substrate forming the panel
body without significant intentional deformation of said preformed
skin.
Inventors: |
Olley; Peter Anthony;
(Essex, GB) ; Wright; Ian Sutherland; (Essex,
GB) |
Correspondence
Address: |
VISTEON
C/O BRINKS HOFER GILSON & LIONE
PO BOX 10395
CHICAGO
IL
60610
US
|
Family ID: |
34954942 |
Appl. No.: |
11/335116 |
Filed: |
January 19, 2006 |
Current U.S.
Class: |
428/104 ; 156/93;
264/152; 296/70; 428/102 |
Current CPC
Class: |
B32B 3/06 20130101; B29C
44/141 20130101; B32B 3/04 20130101; B32B 7/08 20130101; B29C
44/351 20130101; Y10T 428/24479 20150115; Y10T 428/24537 20150115;
Y10T 428/2405 20150115; Y10T 428/24033 20150115; B32B 3/02
20130101; B32B 3/30 20130101; B32B 3/263 20130101; B32B 2605/003
20130101; B32B 3/266 20130101 |
Class at
Publication: |
428/104 ;
296/070; 156/093; 264/152; 428/102 |
International
Class: |
B32B 3/06 20060101
B32B003/06; B29C 65/00 20060101 B29C065/00 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 19, 2005 |
FR |
FR 0500534 |
Claims
1. A method for producing a structural panel for covering or lining
at least part of a component such as an interior door panel, an
instrument panel, a console or flap in a passenger compartment of a
vehicle, the method comprising the steps of: producing a preformed,
one piece skin by molding or forming; forming in an exposed surface
of the skin at least one visual feature simulating a functional
construction element of the structural panel, the visual feature
including a principal formation of a linear structure and a
secondary formation; and mounting the preformed skin on a substrate
forming the body of the panel without significant intentional
deformation of said preformed skin or cover.
2. The method of claim 1 wherein the mounting step include one of
gluing, welding, producing an intermediate cellular bonding layer,
and in situ foaming of the material forming the substrate.
2. The method according to claim 1, wherein said forming step forms
the principal formation as a recessed linear structure and forms
the secondary formations so as to extend generally away from the
longitudinal direction of the principal formation.
3. The method according to claim 1, wherein said forming step forms
the principal formation as a projected linear structure and forms
the secondary formations so as to extend generally away from the
longitudinal direction of the principal formation.
3. The method according to claim 1, wherein in the forming step the
secondary formations are formed in a subsequent operation after
forming of the principal formation.
4. The method according to claim 3 wherein the subsequent operation
is sewing and is performed before the mounting step.
5. The method according to claim 3 wherein the subsequent operation
is molding and is performed before the mounting step.
6. The method according to claim 3, wherein the visual formation
forms the outline of an assembly stitch or seam line in the skin
before the mounting of the skin to the substrate.
7. The method according to claim 1 further comprising the step of
producing, during one or more sewing operation carried out before
attaching the skin or cover to the panel body, at least one
additional decorative stitch extending along at least one side of
the visual feature.
8. The method according to claim 1 further comprising the step of
producing, during one or more molding operation carried out before
attaching the skin or cover to the panel body, at least one
additional decorative stitch extending along at least one side of
the visual feature.
9. The method according to claim 1, wherein before mounting the
skin to the substrate, the method further comprises in applying a
sealant to an unexposed face of the skin in a region of a
through-hole to be formed by the needle during a subsequent sewing
operation.
10. A structural panel for covering or lining at least part of a
component such as an interior door panel, an instrument panel, a
console or flap in a passenger compartment of a vehicle, the panel
comprising: a substrate; a preformed, one piece skin mounted to the
substrate, the skin being formed by molding and including on an
exposed face thereof at least one visual feature simulating a
functional constructional, the visual feature including a principal
formation in the form of a linear structure formed by molding, and
a secondary formation in the form of a false stitch.
11. The panel according to claim 10 wherein the principal formation
is one chosen from the group including slots, grooves, edges, ribs
and folds.
12. The panel according to claim 10 wherein the secondary feature
is formed as a molded feature in the surface of the skin simulating
stitching.
13. The panel according to claim 10 wherein the secondary feature
is formed as stitching extending through the skin.
14. The panel according to claim 10 wherein the secondary feature
is provided within the principal feature.
15. The panel according to claim 10 further comprising a simulated
decorative stitch located adjacent to the visual feature.
16. The panel according to claim 15 wherein the simulated
decorative is formed as a molded decorative stitch in the surface
of the skin.
17. The panel according to claim 10 wherein visual feature includes
a slot having generally tubular cross section with an aperture
toward the exposed face, the secondary feature bridging the
aperture and extend transversely at regular intervals, the
secondary feature being partially exposed through the aperture.
18. The panel according to claim 17 wherein the secondary feature
is formed as stitching extending through the skin.
Description
BACKGROUND
[0001] 1. Field of the Invention
[0002] The present invention relates to the production of articles
of the type that comprise of composite planar or non-planar panels
or covering elements, in particular console panels, instrument
panels or vehicle interior trim panels, and it concerns a method
for producing such a panel, as well as a panel obtained by this
method.
[0003] 2. Related Technology
[0004] The type of panels that the present invention relates to
generally comprise a substrate forming a panel body, generally of a
foamed plastics material or a molded thermoplastics material to
which a surface skin or the like, having a substantially decorative
function (of a synthetic material having the desired appearance),
is attached.
[0005] The conventional method for producing such a panel consists
in producing, by forming (by heating and suction for example) or by
slush casting, an integral skin or cover and mounting it on a
substrate or placing it with such a substrate into a mold for
molding by foaming to produce the finished panel.
[0006] In various applications, in particular vehicle interiors, a
visual appearance is sought which gives the impression of a
traditional production method and an exposed hand-sewn seam.
[0007] The current method for producing such a panel having a
predetermined aesthetic appearance consists, first of all, in
producing a substrate (by molding, forming or the like) the surface
of which substantially has the configuration of the exposed surface
to be obtained and which corresponds thereto absent the thickness
of the decorative skin to be attached. A plurality of skin parts or
decorative covering covers is simultaneously provided by separate
production. These parts are assembled by sewing to form the skin or
cover. The reconstituted skin or cover is then placed onto the face
in question of the panel body and attached thereto. It is necessary
for the skin to stretch to a certain extent to obtain the desired
appearance. This makes the method awkward to carry out and does not
allow seams to be placed near openings, flaps or edges of the
panel. The skin may be attached to the substrate, as mentioned
previously, in various ways such as gluing, welding or attachment
by a layer of foaming material (which makes the surface of the
panel less rigid and softer to touch).
[0008] The applicant's document U.S. Patent Application Publication
No. 2003/0168151 A1, which is herein incorporated by reference,
discloses a method in which a plurality of preformed pieces of
skin, intended to form the basis of a given decorative skin, are
produced (by forming or molding). These pieces are then assembled
to form the decorative skin, the front faces of the seams are
sealed and the skin is then mounted on a substrate forming the
panel body by one of the joining methods described hereinbefore.
FIG. 1 of the accompanying drawings is a partial and schematic view
of a panel section obtained by this method, the section being in
the region of an assembly seam.
[0009] By this improved method, it is possible to produce panels
having exposed seams or decorative, simulated stitching and to
produce panels without such stitching using the same facilities and
the same method. Generally, functional stitching secures two skin
portions together and is reinforced with seam tape or a similar
material. Simulated stitching may be positioned on opposite sides
of the juncture. The shape, number and arrangement of seam lines
may be changed without requiring major modifications to the tools
(for example, when producing a new model). Finally, since no
stretching of the skin is required, it is possible to optionally
position the seam lines relatively close to the openings, edges,
flaps or similar discontinuities.
[0010] However, this method still requires actual seaming
operations (rarely automated), which are tiresome, expensive,
cannot guarantee extensive standardization and generate a
relatively large amount of waste.
SUMMARY
[0011] The object of the present invention is to overcome the
aforementioned drawbacks, while still presenting the advantages of
the improved method described hereinbefore.
[0012] The principal object of the present invention is to provide
a method for producing a panel, in particular a covering panel or
interior vehicle trim, provided with a surface skin or decorative
cover. An integral preformed skin or cover is produced by molding
or forming and includes, in the region of its exposed surface, at
least one visual feature having a linear structure imitating or
simulating a functional constructional or manufacturing line or the
sketch of such a line. This preformed skin or the like is mounted
on a substrate forming the body of the panel by gluing, welding,
producing an intermediate cellular bonding layer, in situ foaming
of the material forming the patent body or the like, without
intentional deformation of the preformed skin or cover.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The invention will be better understood as a result of the
following description, which relates to preferred embodiments,
given by way of non-limiting examples, and explained with reference
to the accompanying schematic drawings, in which:
[0014] FIG. 1 is a schematic illustration of a known prior
construction technique for a seam assembly;
[0015] FIGS. 2A-C and 3A-C are perspective, sectional and plan
views of two variations of a first embodiment of the invention
immediately after molding or forming of the skin and before
attaching the skin to the panel body; and
[0016] FIG. 4 is a detailed sectional view of a first variation of
a second embodiment of the invention.
DETAILED DESCRIPTION
[0017] The construction for producing a composite panel 1 according
to the invention generally includes producing an integral preformed
skin or cover 2 by molding or forming. The skin 2 includes, in the
region of its exposed surface, at least one visual feature 3 having
a linear structure imitating or simulating a functional
constructional or manufacturing line, or the appearance of such a
line. This preformed skin 2 is mounted on a substrate 4 forming the
body of the panel, by gluing, welding, producing an intermediate
cellular bonding layer 4', in situ foaming of the material forming
the panel body or the like, without significant intentional
deformation of said preformed skin 2.
[0018] By forming the skin 2 all in one piece and in a preformed
manner, actual assembly operation(s) via sewing are eliminated, the
structural integrity is preserved (absence of an assembly interface
and discontinuity) and no deformation or stretching is required
when this skin 2 is applied to the substrate 4.
[0019] According to a first embodiment shown in FIGS. 2 (first
variant) and 3 (second variant) of the accompanying drawings, at
least one or each visual feature 3 is produced by molding or
forming and includes a principal protruding (FIGS. 3A-C) or
recessed (FIGS. 2A-C) linear formation 5, i.e. a slot, groove, rib,
edge or fold. The linear formation 5 includes a plurality of
secondary formations 6 imitating assembly seam or stitch points.
These secondary formations 6 may extend perpendicular or at an
angle to the longitudinal direction of the principal formation 5.
Manufactured in this manner, the desired final visual feature 3 is
immediately present after the molding or forming of the skin 2.
[0020] As seen in FIGS. 2A-2C, this visual feature 3 may, for
example, be a slot 5 with material bridges 6 simulating an assembly
stitch. The visual feature thus resembles a seam between two pieces
of skin 2.
[0021] As seen in FIGS. 3A-3C, this visual feature 3 may be in the
form of an excessive build-up 5 simulating a fold and limiting of
the partial overlap of two pieces of skin, with or without an
associated assembly with a seam line imitation 6.
[0022] Possibly, the formation 5 also includes needle marks or
traces 5' further visually forming the sketch of an assembly stitch
or seam line. The secondary formations 6 and/or the needle marks or
traces 5' may be produced, by way of non-limiting example, by using
heat and with the skin 2 under pressure. This operation may be
carried out separately or be incorporated in the sewing
operation.
[0023] It is further possible to provide one or more decorative
seam or stitch line 8, by molding or forming, on opposite or a
single side of the visual feature 3. In an advantageous manner, it
may also be envisaged to carry out the operations for forming the
false assembly seam 5', 6 in the region of the formation 5,
simultaneously to the production of the additional decorative seam
line or lines 8.
[0024] According to a second embodiment seen in FIG. 4, the skin
2'' has at least one or each visual feature 3'' defining a
protruding or recessed linear formation 5'', formed by molding or
obtained by forming, i.e. a slot, groove, rib, edge or fold. This
formation 5'', however is subjected to a subsequent operation, for
example actual sewing, stitching or notching, so as to produce, in
the region of this formation 5'', secondary formations, a
non-functional stitch or seam line, 7 extending perpendicularly or
at an angle to the longitudinal direction of the principal
formation 5''. Notably, non-functional stitch or seam line 7 is
produced during an actual subsequent stitching or sewing operation,
subsequent to molding but before attachment of the skin 2'' to the
body 4 or in situ formation thereof. Since the skin 2'' is one
piece, secondary formations 7 only imitate an assembly seam or
stitch points.
[0025] As shown in FIG. 4 of the accompanying drawings, the method
may also include in producing, during one or more stitching or
sewing operation(s) carried out before attaching the skin 2'' to
the panel body 4, at least one additional decorative stitch or seam
line 8'' extending along at least one side of the visual feature
3'' or the formation 5'' and having a linear structure.
[0026] In order to preserve the water tightness of the skin 2'',
the method may also consist, before attaching the skin 2'' to the
panel body 4, applying a sealant 9, in a continuous or
discontinuous manner, to the unexposed face of the skin 2'' in the
region of a through-hole 10 formed by the needle or the needles
used in providing the decorative stitch or seam line(s) 8.
Nonetheless, due to the absence of an assembly interface and
structural discontinuity in the single-piece skin 2, only localized
applications of strips, liquid substance or similar sealing
products is necessary.
[0027] Via the above construction, the present invention provides a
structural panel 1 for covering or lining a vehicle, in particular
an interior door panel, a panel forming a flap or console part, an
instrument panel or passenger compartment panel, provided with a
decorative skin 2'' on the surface.
[0028] According to the invention, this panel 1 is characterized in
that it comprises a substrate forming the panel body 4 on which the
skin 2, that is preformed in one piece, is mounted. In the region
of its exposed face is at least one visual feature 3 having a
linear structure 5 imitating or simulating a functional
constructional or manufacturing line. The visual feature 3 consists
at least partially of a formation or formations 5, 6 formed by
molding. The or each visual feature 3 comprises, on the one hand, a
principal formation 5 formed by molding or produced by forming and
chosen from the group including slots, grooves, edges, ribs or
folds, having a rectilinear or non-rectilinear extension, and, on
the other hand, a plurality of secondary formations 6, also formed
by molding or produced by forming, and possibly completed by a
false assembly marks 5' and decorative stitches 8.
[0029] This panel 1 would preferably be obtained by means of the
method described above.
[0030] In an alternative embodiment, illustrated in FIG. 4, the
visual feature 3'' comprises of a slot 5'' having a triangular or
tubular cross section, opened on the exposed face by an aperture 11
and across which actual decorative stitch or seam points 6'',
extend transversely at regular intervals. These stitch or seam
points 6'' may be partially exposed through the aperture 11.
[0031] With this invention, it is also possible, in particular, to
provide an additional non-functional stitch line produced during an
actual sewing operation before attaching the skin to the body of
the panel.
[0032] The invention is, of course, not limited to the embodiments
described and illustrated in the accompanying drawings.
Modifications are possible, in particular as regards the
constitution of the various elements or by substitution of
technical equivalents, without thereby departing from the scope of
the invention.
* * * * *